Article of footwear with first and second outsole components and method of manufacturing an article of footwear

ABSTRACT

A sole structure for an article of footwear comprises a midsole including a polymeric bladder element enclosing a fluid-filled interior cavity, a first outsole component secured to a bottom surface and to a side surface of the polymeric bladder element, and a second outsole component. The first outsole component includes a first base, and a wall integral with the first base. The second outsole component includes a second base secured to the first base, and a wall integral with the second base and secured to the outer surface of the wall of the first outsole component. A method of manufacturing the article of footwear includes thermoforming the bladder element and the first outsole component, and securing the second outsole component to the first outsole component.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 15/070,082, filed Mar. 15, 2016, now U.S. Pat. No. 9,981,437,which application is a continuation-in-part of U.S. patent applicationSer. No. 14/641,881, filed on Mar. 9, 2015, now U.S. Pat. No. 9,987,814which application is a continuation-in-part of U.S. patent applicationSer. No. 14/641,789, filed on Mar. 9, 2015, now U.S. Pat. No. 9,750,307,issued Sep. 5, 2017, which application is a continuation-in-part of U.S.patent application Ser. No. 13/773,360 filed on Feb. 21, 2013, now U.S.Pat. No. 9,420,848, issued Aug. 23, 2016, all of which applications areincorporated by reference in their entireties.

TECHNICAL FIELD

The present teachings generally relate to an article of footwearincluding a sole structure, and to a method of manufacturing the articleof footwear.

BACKGROUND

Footwear typically includes a sole structure configured to be locatedunder a wearer's foot to space the foot away from the ground or floorsurface. Athletic footwear in particular sometimes utilizes polyurethanefoam, rubber, or other resilient materials in the sole structure toprovide cushioning.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a cross-sectional view of an article of footwear including aco-molded article;

FIG. 2 is a cross-sectional view of a co-molded article;

FIG. 3 is a cross-sectional view of an open mold illustrating arelationship of parts for producing an article;

FIG. 4 is a cross-sectional view of a closed mold illustrating arelationship of parts for producing the article of FIG. 3;

FIG. 5 is a cross-sectional view of an open mold illustrating arelationship of parts for producing an article;

FIG. 6 is a cross-sectional view of a closed mold illustrating arelationship of parts for producing the article of FIG. 5;

FIG. 7 is a cross-sectional view of an open mold illustrating arelationship of parts for producing an article of the disclosure;

FIG. 8 is a cross-sectional view of one part of an open moldillustrating a relationship of parts for producing the article of FIG.7;

FIG. 9 is a cross-sectional view of a closed mold illustrating arelationship of parts for producing the article of FIG. 7;

FIG. 10 is a cross-sectional view of an open mold illustrating arelationship of parts for producing another article of the disclosure;

FIG. 11 is a cross-sectional view of a closed mold illustrating arelationship of parts for producing the article of FIG. 10;

FIG. 12 is a cross-sectional view of an open mold illustrating arelationship of parts for producing still another article of thedisclosure;

FIG. 13 is a cross-sectional view of a closed mold illustrating arelationship of parts for producing the article of FIG. 12;

FIG. 14 is a bottom view of a sole structure for an article of footwearincluding a forefoot sole structure and a heel sole structure attachedto a footwear upper;

FIG. 15 is a lateral side view of an article of footwear including thesole structure of FIG. 14 attached to a footwear upper;

FIG. 16 is a perspective view of a lower surface of a forefoot bladderelement of the sole structure of FIG. 14;

FIG. 17 is a perspective view of a lower surface of a first outsolecomponent of the forefoot sole structure of FIG. 14;

FIG. 18 is perspective view of an upper surface of the first outsolecomponent of FIG. 17;

FIG. 19 is a cross-sectional perspective illustration of the firstoutsole component of FIG. 18 taken at lines 19-19 in FIG. 18;

FIG. 20 is a perspective view of a lower surface of a heel bladderelement of the sole structure of FIG. 14;

FIG. 21 is a perspective view of a lower surface of a first outsolecomponent of the heel sole structure of FIG. 14;

FIG. 22 is perspective view of an upper surface of the first outsolecomponent of FIG. 21;

FIG. 23 is a cross-sectional view of the sole structure of FIG. 14 takenat lines 23-23 in FIG. 14;

FIG. 24 is a cross-sectional view of the sole structure of FIG. 14 takenat lines 24-24 in FIG. 14;

FIG. 25 is a cross-sectional view of an injection mold for the firstoutsole component of FIG. 17;

FIG. 26 is a cross-sectional view of an injection mold for the firstoutsole component of FIG. 22;

FIG. 27 is a cross-sectional and exploded view of an open thermoformingmold illustrating a relationship of some of the components of the solestructure of FIG. 14; and

FIG. 28 is a cross-sectional view of the mold and components of FIG. 27with the mold in a closed position.

DESCRIPTION

A sole structure for an article of footwear includes a midsole having apolymeric bladder element enclosing a fluid-filled interior cavity, afirst outsole component, and a second outsole component. The firstoutsole component is secured to a bottom surface and to a side surfaceof the polymeric bladder element. The first outsole component includes afirst base, and a wall integral with the first base. The second outsolecomponent includes a second base secured to the first base, and a wallintegral with the second base and secured to the outer surface of thewall of the first outsole component.

In an embodiment, the first outsole component may be a first material,such as a thermoplastic polyurethane, and the second outsole componentmay be a second material, such as rubber.

In an embodiment, the bladder element has an arcuate tubular portion ina forefoot region of the sole structure. The side surface of the bladderelement is at an inner curved wall of the bladder element at the arcuatetubular portion. In this configuration, the wall of the second outsolecomponent supports and reinforces the inner curved wall of the bladderelement, such as during dorsiflexion of the forefoot region.

In an embodiment, the first base has integral tread elements protrudingat a first portion of a bottom surface of the first base, but a secondportion of the bottom surface is free of any tread elements. The wall ofthe first outsole component has an outer surface adjacent the secondportion of the bottom surface. The second base of the second outsolecomponent is secured to the second portion of the bottom surface of thefirst base. Accordingly, the first tread elements do not interfere withthe second base. Moreover, a ground-engaging surface of the solestructure includes the integral tread elements of the first outsolecomponent and includes the second outsole component. The second outsolecomponent may also have tread elements that are included in theground-engaging surface.

In an embodiment, the first outsole component is a first material andthe second outsole component is a second material different than thefirst material. For example, the first outsole component may be athermoplastic polyurethane, and the second outsole component may berubber. The second material may be selected to provide durability to theground-engaging surface and reinforcing support to tune the cushioningresponse of the first outsole component.

In an embodiment, the outer surface of the wall of the first outsolecomponent has a recess adjacent the second portion of the bottom surfaceof the first outsole component. The wall of the second outsole componentmay be secured to the outer surface of the wall of the first outsolecomponent in the recess. The wall of the second outsole component isthus nested in the recess, which protects the wall of the second outsolecomponent from forces that could cause delamination. In one embodiment,the wall of the second outsole component has a first thickness, therecess has a first depth, and the first thickness is greater than thefirst depth so that the second outsole component protrudes outward ofthe first outsole component at the wall of the first outsole component.

In an embodiment, the wall of the first outsole component is an outerwall of the first outsole component and the wall of the second outsolecomponent is an outer wall of the second outsole component. The firstoutsole component has an inner wall integral with the first base, andthe recess extends only partway up the outer wall of the first outsolecomponent, along the bottom surface of the base, and up the inner wallof the first outsole component. The second outsole component has aninner wall integral with the second base and secured to an outer surfaceof the inner wall of the first outsole component. The inner wall of thesecond outsole component extends further upward along the first outsolecomponent than the outer wall of the second outsole component.

In an embodiment, the polymeric bladder element is configured so that atleast a portion of the fluid-filled interior cavity has a U shape withan arcuate portion at an outer periphery of the sole structure. Thefirst outsole component has a U shape corresponding to the U shape ofthe fluid-filled interior cavity with the wall of the first outsolecomponent at the arcuate portion of the fluid-filled interior cavity.

In an embodiment, the second outsole component has a plurality ofintegral second tread elements protruding from a bottom surface of thesecond outsole component. The first tread elements and the second treadelements establish a ground-engaging surface of the sole structure.

The article of footwear may include an upper. The midsole, the firstoutsole component, and the second outsole component may be configured asa forefoot sole structure secured to a forefoot region of the upper, andthe sole structure may also include a heel sole structure secured to aheel region of the upper. The heel sole structure may include a midsolewith a polymeric bladder element enclosing a separate fluid-filledinterior cavity isolated from the fluid-filled interior cavity of thepolymeric bladder element of the forefoot sole structure, a firstoutsole component secured to a bottom surface of the bladder element ofthe heel sole structure, and a second outsole component secured to thefirst outsole component of the heel sole structure.

A method of manufacturing an article of footwear comprises placing apreformed first outsole component into a thermoforming mold. Thepreformed first outsole component has a base with integral treadelements protruding from a first portion of a bottom surface of thebase, and with a second portion of the bottom surface free of any treadelements. The first outsole component also has a wall integral with thebase and adjacent the second portion of the bottom surface. The methodincludes placing polymeric material in the thermoforming mold with thefirst outsole component, and closing the thermoforming mold to enclosethe polymeric material and the first outsole component in a mold cavity.A vacuum is applied to conform a first portion of the polymeric materialto a first mold surface of the thermoforming mold and to conform asecond portion of the polymeric material to an upper surface of thefirst outsole component and to a second mold surface of thethermoforming mold, with an interior cavity between the first portionand the second portion.

The first portion of the polymeric material may be a first polymericsheet, and the second portion of the polymeric material may be a secondpolymeric sheet. The method may further include thermally bonding thefirst polymeric sheet to the second polymeric sheet to enclose theinterior cavity, thermally bonding the lower surface of the secondpolymer sheet to the upper surface of the first outsole component, andremoving the thermally bonded upper and lower polymer sheets and firstoutsole component from the thermoforming mold as a unit after apredetermined cooling period.

A second outsole component may be positioned on the second portion ofthe bottom surface of the first outsole component, and adhered to thefirst outsole component. For example, positioning the second outsolecomponent may be by nesting the second outsole component in a recess inthe outer surface of the wall of the first outsole component. Nestingthe second outsole component in the recess may include placing an upperedge of the second outsole component along a lip of the first outsolecomponent at an upper extent of the recess.

The method may include securing a footwear upper to an upper surface ofthe first polymer sheet. The first and the second polymer sheets, thefirst outsole component, and the second outsole component may beconfigured as a forefoot sole structure and secured to a forefoot regionof the footwear upper, and the method may include securing a heel solestructure to a heel region of the footwear upper with a forward edge ofthe heel sole structure adjacent a rearward edge of the forefoot solestructure.

The second mold surface may have a positioning marker, and placing thefirst outsole component into the thermoforming mold may include placinga predetermined portion of the first outsole component at thepositioning marker, thereby orienting the first outsole component in apredetermined position in the thermoforming mold.

The above features and advantages and other features and advantages ofthe present teachings are readily apparent from the following detaileddescription of the modes for carrying out the present teachings whentaken in connection with the accompanying drawings.

“A,” “an,” “the,” “at least one,” and “one or more” are usedinterchangeably to indicate that at least one of the items is present. Aplurality of such items may be present unless the context clearlyindicates otherwise. All numerical values of parameters (e.g., ofquantities or conditions) in this specification, unless otherwiseindicated expressly or clearly in view of the context, including theappended claims, are to be understood as being modified in all instancesby the term “about” whether or not “about” actually appears before thenumerical value. “About” indicates that the stated numerical valueallows some slight imprecision (with some approach to exactness in thevalue; approximately or reasonably close to the value; nearly). If theimprecision provided by “about” is not otherwise understood in the artwith this ordinary meaning, then “about” as used herein indicates atleast variations that may arise from ordinary methods of measuring andusing such parameters. In addition, a disclosure of a range is to beunderstood as specifically disclosing all values and further dividedranges within the range. All references referred to are incorporatedherein in their entirety.

The terms “comprising,” “including,” and “having” are inclusive andtherefore specify the presence of stated features, steps, operations,elements, or components, but do not preclude the presence or addition ofone or more other features, steps, operations, elements, or components.Orders of steps, processes, and operations may be altered when possible,and additional or alternative steps may be employed. As used in thisspecification, the term “or” includes any one and all combinations ofthe associated listed items. The term “any of” is understood to includeany possible combination of referenced items, including “any one of” thereferenced items. The term “any of” is understood to include anypossible combination of referenced claims of the appended claims,including “any one of” the referenced claims.

Those having ordinary skill in the art will recognize that terms such as“above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., may beused descriptively relative to the figures, without representinglimitations on the scope of the invention, as defined by the claims.

In an embodiment, the shaped article may be a cushioning layer and anoutsole of an article of footwear. FIG. 1 illustrates such anembodiment. FIG. 1 is a cross-sectional view of an article of footwearincluding a co-molded article. An article of footwear 100 includes anupper 120 and a sole structure 130. Upper 120 provides a comfortable andsecure covering for a foot of a wearer. As such, the foot may be locatedwithin upper 120 to effectively secure the foot within article offootwear 100 or otherwise unite the foot and article of footwear 100.Sole structure 130 is secured to a lower area of upper 120 and extendsbetween the foot and the ground to attenuate ground reaction forces(i.e., cushion the foot), provide traction, enhance stability, andinfluence the motions of the foot, for example. In effect, solestructure 130 is located under the foot and supports the foot.

Upper 120 is depicted as having a substantially conventionalconfiguration. A majority of upper 120 incorporates various materialelements (e.g., textiles, foam, leather, and synthetic leather) that arestitched or adhesively bonded together to produce an interior void forsecurely and comfortably receiving a foot. The material elements may beselected and located in upper 120 to selectively impart properties ofdurability, air-permeability, wear-resistance, flexibility, and comfort,for example. The void in upper 120 is shaped to accommodate the foot.When the foot is located within the void, therefore, upper 120 extendsalong a lateral side of the foot, along a medial side of the foot, overthe foot, around the heel, and under the foot. A lace 122 extends over atongue 123. Lace 122 and the adjustability provided by tongue 123 may beutilized in a conventional manner to modify the dimensions of theinterior void, thereby securing the foot within the interior void andfacilitating entry and removal of the foot from the interior void.Sockliner 125 may enhance the comfort of article of footwear 100.

Further configurations of upper 120 may also include one or more of (a)a toe guard positioned in forefoot region and formed of a wear-resistantmaterial, (b) a heel counter located in heel region for enhancingstability, and (c) logos, trademarks, and placards with careinstructions and material information. Given that various aspects of thepresent discussion primarily relate to sole structure 130, upper 120 mayexhibit the general configuration discussed above or the generalconfiguration of practically any other conventional or non-conventionalupper. Accordingly, the structure of upper 120 may vary significantly.

Sole structure 130 includes outsole 160 attached to fluid-filled chamber140. Outsole 160 has ground-engaging protuberances 135 associatedtherewith.

FIG. 2 illustrates an alternative embodiment of a tank-type article 200having top 210 associated with tank 220. Tank 220 is at least partiallysurrounded by case 230 having protuberances 235 extending therefrom.FIG. 2, FIG. 5, FIG. 6, FIG. 12, and FIG. 13, and the accompanyingdescriptions, explain this alternative embodiment.

FIG. 3 and FIG. 4 illustrate a way of producing a sole structure such asbut not limited to sole structure 130 of FIG. 1. FIG. 3 and FIG. 4depict a cross-section of a mold for co-molding fluid-filled chamber 140with outsole 160 with protuberances 135 thereon. Outsole 160 may beproduced by a number of pre-formed objects or elements assembled in themold. In some embodiments, outsole 160 wraps at least a portion of edge143 on fluid-filled chamber 140. Molded structure 131 is an embodimentof an article having outsole 160 wrapping a significant portion of theedge of fluid-filled chamber 140. As the components are produced ofthermoplastic materials, they may be softened to aid in producing theshapes in the mold.

FIG. 3 and FIG. 4 are cross-sectional depictions of mold 300 forstructure 131. As shown in FIG. 3 and FIG. 4, fluid-filled chamber 140is co-molded with outsole 160 present in the mold. Adhesive also may bepresent on appropriate surfaces.

Stated generally, the co-molded article may be produced in a two-piecemold with an upper and a lower mold portion by placing outsole elementsinto the lower mold portion, then placing the layers that will form thefluid-filled chamber 140 on top of the outsole elements. The mold isthen closed so that the upper and lower mold portions abut one another.The mold is shaped so that the closing the mold results in the formationof the chamber. Fluid under pressure is then introduced into the chamberso that the inflation of the chamber forces the upper surface of thechamber into conforming relationship with the underside of the uppermold portion, and also forces the lower portion of the chamber intoconforming relationship with the outside elements underneath. Energy maybe applied to the mold as heat, radio frequency, or the like to co-moldthe first and second elements together with the chamber inflated andpushing the article against the mold surfaces and the outsole elements.The second element portions such as layers of polymer may be provided inthe mold as a precursor for the completed product. Such precursor may beformed in the mold as part of the co-molding process as describedherein, or may be provided as completely pre-formed chamber that isready for inflation.

A variety of manufacturing processes may be utilized to produce solestructure 131. In some embodiments, mold 300 that may be utilized in themanufacturing process is depicted as including a first mold portion 310and a second mold portion 320. Mold 300 is utilized to producefluid-filled chamber 140 from a first polymer layer 410 and a secondpolymer layer 420, which are the polymer layers producing fluid-filledchamber upper surface 141 and fluid-filled chamber lower surface 142,respectively. More particularly, mold 300 facilitates the manufacturingprocess by (a) shaping first polymer layer 410 and second polymer layer420 in areas corresponding with edges 143 of the fluid-filled chambers140, flange 146, and conduits between chambers, and (b) joining firstpolymer layer 410 and second polymer layer 420 in areas correspondingwith flange 146 and web area 1147.

Various surfaces or other areas of mold 300 will now be defined for usein discussion of the manufacturing process. First mold portion 310includes a first mold portion surface 350, which shapes the top surfaceof the co-molded article. Various parts of a first element, such asoutsole 160, and a second element, such as a fluid-filled chamber 140,are illustrated in FIG. 3. Second mold portion 320 is shaped so as toreceive protuberances 135 in close engagement with slots 325 in secondmold portion 320. Outsole 160 then is placed in the mold. Outsole 160fits within undercut 335. Then, second element precursor or firstpolymer layer 410 is put into place to become the top surface of thearticle and second element precursor or second polymer layer 420produces the bottom or lower surface 142 of the second element, hereinthe fluid-filled chamber, when the article is molded.

As first mold portion 310 and second mold portion 320 are moved towardeach other, various techniques may be utilized to draw first polymerlayer 410 and second polymer layer 420 against surfaces of first moldportion 310 and second mold portion 320, thereby beginning the processof shaping first polymer layer 410 and second polymer layer 420. Forexample, air may be partially evacuated from the areas between (a) firstmold portion 310 and first polymer layer 410 and (b) second mold portion320 and second polymer layer 420. More particularly, air may bewithdrawn through various vacuum ports in first mold portion 310 andsecond mold portion 320. By removing air, first polymer layer 410 isdrawn into contact with the surfaces of first mold portion 310 andsecond polymer layer 420 is drawn into contact with the surfaces ofsecond mold portion 320. As another example, fluid may be injected intothe area between first polymer layer 410 and second polymer layer 420,thereby elevating the pressure between first polymer layer 410 andsecond polymer layer 420. During a preparatory stage of this process, aninjection needle may be located between first polymer layer 410 andsecond polymer layer 420, and a fluid, such as a gas, a liquid, or agel, for example, or a blend thereof, then may be ejected from theinjection needle such that first polymer layer 410 and second polymerlayer 420 engage the surfaces of mold 300. Each of these techniques maybe used together or independently.

As first mold portion 310 and second mold portion 320 continue to movetoward each other, first polymer layer 410 and second polymer layer 420are pinched between first mold portion 310 and second mold portion 320.More particularly, first polymer layer 410 and second polymer layer 420are compressed between pinch surface 330 and pinch edge 360. In additionto beginning the process of separating excess portions of first polymerlayer 410 and second polymer layer 420 from portions that formfluid-filled chamber 140, the pinching of first polymer layer 410 andsecond polymer layer 420 begins the process of bonding or joining firstpolymer layer 410 and second polymer layer 420 in the area of flange146.

Following the pinching of first polymer layer 410 and second polymerlayer 420, first mold portion 310 and second mold portion 320 proceedwith moving toward each other and into a closed configuration, asdepicted in FIG. 4. As the mold closes, pinch surface 330 contacts andslides against a portion of second seam-forming surface 370. The contactbetween pinch surface 330 and second seam-forming surface 370effectively severs excess portions of first polymer layer 410 and secondpolymer layer 420 from portions that form fluid-filled chamber 140. Thematerial forming first polymer layer 410 and second polymer layer 420compacts or otherwise collects to form flange 146. In addition toforming flange 146, first polymer layer 410 and second polymer layer 420are (a) shaped to produce fluid-filled chamber 140 and (b) compressedand joined to produce web area 1147.

When producing of fluid-filled chamber 140 is complete, mold 300 isopened. Fluid then may be injected into fluid-filled chamber 140 topressurize forefoot component fluid-filled chambers, thereby completingthe manufacture of structure 131. As a final step in the process,structure 131 may be incorporated into a sole structure of an article offootwear 100.

Co-molded articles may have many uses. FIG. 5 illustrates a tank orother container. FIG. 5 depicts molding of a tank or other container.Mold 600 includes first mold portion 610 having mold surface 650. Secondmold portion 620 includes slots 625 to securely engage protuberances 535on first element 560. Second polymer layer 520 and first polymer layer510 are in position in the open mold. After first element 560 isinserted into the mold, second polymer layer 520 will form the layer ofthe tank in contact with first element 560. First polymer layer 510 willform the upper surface of the tank.

FIG. 6 illustrates mold 600 closed to form tank or article 570 withinthe mold. Surface 650 of first mold portion 610 shapes upper surface 572of top layer 506 of the article. A sealed tank may be produced by fusingor adhering the polymer layers at flange 546, which may extend aroundthe periphery of the tank. Protuberances 535 on first element 560 fitclosely in slots 625 in the second portion 620 of the mold.

Whereas the method and the molds described previously shape partssatisfactorily, the skilled practitioner recognizes that it may bedifficult to extract the co-molded article from the mold. So long as theco-molded article is sufficiently flexible and resilient, the articlemay be deformed slightly to remove it from the undercut mold. However,protuberances formed on the outer surface of a co-molded article inslots and other features that extend the article into the mold may makeit very difficult to remove the article from the mold.

Therefore, this disclosure is directed to co-molding articles in a moldthat minimizes contact between protuberances on the article and surfacesof the mold. The co-molded article may include a pre-formed article. Insome embodiments, the pre-formed article is capable of essentiallyretaining its shape. In such embodiments, a first element may be apre-formed element placed in a mold wherein the interior surface isessentially uninterrupted by slots and other features in whichprotuberances may be formed. Rather, in such embodiments, the firstelement is placed in the mold with minimal interference or contactbetween the protuberances and the mold. The element essentially retainsits shape when placed in the mold. In some embodiments, a base or endsurface of a protuberance may contact the surface of the mold, but thesides of the protuberances are essentially free of contact with themold. In this way, the co-molded article may be easily removed from themold.

In some embodiments, a sole structure for an article of footwear may bemade in accordance with a method for co-molding a first element and asecond element to produce a co-molded article. FIG. 7, FIG. 8, and FIG.9 depict stages of this method for co-molding a sole structure of anarticle of footwear. Mold 700 may have a first mold portion 710 and asecond mold portion 720. Shape 750 on first mold portion 710 may formthe top surface 741 of the co-molded article.

The first element 760 may have top surface 761, edge surface 762, andprotuberance 735 having base 737 opposite top surface 761. Edge surface762 may extend any distance away from top surface 761. First element 760also may have bottom surface 794. The second element 765 may have edge743, upper surface 741, and lower surface 764.

Any suitable polymeric material may be used to produce the firstelement, which would be an outsole as depicted in FIG. 7. Although eachfeature is illustrated in the figures as a single layer, each suchfeature may comprise a single layer of material or multiple layers, andmay be thermoformed or otherwise shaped. Examples of polymeric materialsthat may be utilized for such a sole structure include any ofpolyurethane, urethane, polyester, polyester polyurethane, polyether,polyether polyurethane, latex, polycaprolactone, polyoxypropylene,polycarbonate macroglycol, and blends thereof. These and other polymericmaterials, an exemplary embodiment, and a method for manufacturing them,may be found in U.S. Pat. No. 9,420,848 to Campos II et al., theentirety of which is hereby incorporated by reference.

An outsole typically may be produced from any durable material.Typically, outsole material is tough, durable, resistant to abrasion andwear, flexible, and skid-resistant. In some embodiments, polyurethanematerials sufficiently durable for ground contact. Suitablethermoplastic polyurethane elastomer materials include Bayer Texin® 285,available from Bayer. Elastollan® SP9339, Elastollan® SP9324, andElastollan® C705, available from BASF, also are suitable. Polyurethaneand other polymers that may not be sufficiently durable for directground contact may be used to produce part of an outsole in someembodiments. In such embodiments, a rubber outsole may be adhered orcemented onto the outsole. In embodiments, the outsole material istransparent or translucent. In embodiments, ground-engaging lugs may beintegrally produced as part of an outsole, or may be separately producedand adhered to the outsole. The outsole may have a texturedground-engaging surface to improve traction.

As depicted in FIG. 7, FIG. 8, and FIG. 9, first element 760 may be anoutsole. For such an embodiment, in accordance with the method, outsole760 is located in second mold portion 720 with base 737 of protuberance735 in contact with surface 780 of second mold portion 720. Surface 780of second mold portion 720 is shaped so as to not contact a significantfraction of protuberance 735 other than base 737. Protuberance 735 maybe considered to be a ground-engaging portion, with an end thereof beinga base 737 that engages the ground. As depicted with particularity inFIG. 7 and FIG. 8, outsole 760 may have a slight arc or curve that causeedge 762 to not contact edge 862 of second mold portion 720. Not allbases 737 may touch surface 780 simultaneously before molding with asecond element.

Precursor for a second element, a fluid-filled chamber, is placed in themold and the mold is closed. First polymer layer 810 may form topsurface 741 of second element 765. Second polymer layer 820 may formedge 743 of second element 765 and lower surface or bottom 764 of secondelement or fluid-filled chamber 765.

Each of first polymer layer 810 and second polymer layer 820 areinitially located between first mold portion 710 and second mold portion720, which are in a spaced or open configuration, as depicted in FIG. 7.In this position, first polymer layer 810 is positioned adjacent orcloser to first mold portion 710, and second polymer layer 820 ispositioned adjacent or closer to second mold portion 720. A shuttleframe or other device may be utilized to properly position first polymerlayer 810 and second polymer layer 820. As part of the manufacturingprocess, one or both of first polymer layer 810 and second polymer layer820 are heated to a temperature that facilitates shaping and bonding. Asan example, various radiant heaters or other devices may be utilized toheat first polymer layer 810 and second polymer layer 820, possiblyprior to being located between first mold portion 710 and second moldportion 720. As another example, mold 700 may be heated such thatcontact between mold 700 and first polymer layer 810 and second polymerlayer 820 at a later portion of the manufacturing process raises thetemperature to a level that facilitates shaping and bonding.

Once first polymer layer 810 and second polymer layer 820 are properlypositioned, first mold portion 710 and second mold portion 720 translateor otherwise move toward each other and begin to close on first polymerlayer 810 and second polymer layer 820. Fluid under pressure may beintroduced into fluid-filled chamber 765 to conform upper surface 741 offluid-filled chamber 765 to the shape 750 of the first mold portion 710,to conform lower surface 764 of fluid-filled chamber or second element765 to the shape of top surface 761 of first element 760, and to conformedge 743 of fluid-filled chamber 765 to edge surface 762 of firstelement 760 or edge 862 of second mold portion 720.

Upon injection of fluid into fluid-filled chamber 765, second polymerlayer 820 may be urged toward top surface 761 of outsole 760, edge 762of outsole 760, and edge 862 of second mold portion 720. As the pressurein fluid-filled chamber 765 increases, pressure on outsole top surface761 may urge bases 737 on protuberances 735 toward surface 780 of secondmold portion 720. Similarly, pressure in fluid-filled chamber 765 mayurge edge 743 of fluid-filled chamber 765 toward edge 762 of outsole760, and may urge both toward edge 862 of second mold portion. Edge 743also may be urged into contact with edge 862 of second mold portion 720where edge 762 of outsole 760 does not preclude contact therewith.

As can be seen with particularity in FIG. 8 and FIG. 9, bottom surface794 of outsole 760 typically may not contact bottom surface 780 ofsecond mold portion 720 even after the fluid-filled chamber is fullymolded. Although outsole 760 is held in position, demolding is carriedout with less force than demolding from a mold that exerts forces onsuch protuberances, such as in FIG. 3 and FIG. 4. Fluid pressure influid-filled chamber 765 may be adjusted after the sole structure isdemolded.

FIG. 10 and FIG. 11 illustrate another embodiment of a co-molded articlein the produce of a sole structure for an article of footwear that maybe made in accordance with a method for co-molding a first element and asecond element to produce a co-molded article. Mold 1100 may have afirst mold portion 1110 and a second mold portion 1120. Shape 1150 onfirst mold portion 1110 may produce the top surface 1041 of theco-molded article.

Outsole 1060 may have top surface 1061, edge surface 1062, andprotuberance 1035 having base 1037 opposite top surface 1061. The secondelement 1065 may have edge 1043, upper surface 1041, and lower surface1064. Any suitable polymeric material may be used to produce the solestructure, as described with regard to FIG. 7, FIG. 8, and FIG. 9.

In some embodiments, such as in the embodiments depicted in FIG. 10 andFIG. 11, first element 1060 may be an outsole. For such an embodiment,in accordance with the method, outsole 1060 is located in second moldportion 1120 with base 1037 of protuberance 1035 in contact with surface1180 of second mold portion 1120. Surface 1180 of second mold portion1120 is shaped so as to not contact a significant fraction ofprotuberance 1035 other than base 1037. Protuberance 1035 may be aground-engaging portion, with the end thereof being a base 1037 thatengages the ground. As depicted with particularity in FIG. 10, outsole1060 may have a slight arc or curve that cause edge 1062 to not contactedge 1162 of second mold portion 1120. Outsole 1060 may include flange1063, which may provide additional support to the sole structure.

Precursor for a second element, a fluid-filled chamber, is placed in themold and the mold is closed. First polymer layer 1010 may produce topsurface 1041 of second element 1065. Second polymer layer 1020 may formedge 1043 and lower surface or bottom 1064 of second element orfluid-filled chamber 1065.

Each of first polymer layer 1010 and second polymer layer 1020 areinitially located between each of first mold portion 1110 and secondmold portion 1120, which are in a spaced or open configuration, asdepicted in FIG. 10 and FIG. 11. The polymer layers are placed andheated as described in relationship to FIG. 7, FIG. 8, and FIG. 9.

Fluid under pressure may be introduced into fluid-filled chamber 1065 asit forms to conform upper surface 1041 of fluid-filled chamber 1065 tothe shape 1150 of the first mold portion, to conform lower surface 1064of fluid-filled chamber or second element 1065 to the shape of topsurface 1061 of first element or outsole 1060, and to conform edge 1043of fluid-filled chamber 1065 to edge surface 1062 of outsole 1060 oredge 1162 of second mold portion 1120.

Upon injection of fluid into fluid-filled chamber 1065, second polymerlayer 1020 may be urged toward top surface 1061 of outsole 1060, edge1062 of outsole 1060, and edge 1162 of second mold portion 1120. As thepressure in fluid-filled chamber 1165 increases, pressure on outsole topsurface 1061 may urge bases 1037 on protuberances 1035 toward surface1080 of second mold portion 1120. Similarly, pressure in fluid-filledchamber 1065 may urge edge 1043 of fluid-filled chamber 1065 toward edge1062 of outsole 1060, and may urge both toward edge 1162 of second moldportion. Edge 1043 also may be urged into contact with edge 1162 ofsecond mold portion 1120 where edge 1062 of outsole 1060 does notpreclude contact therewith.

As can be seen with particularity in FIG. 11, bottom surface 1094 ofoutsole 1060 typically may not contact bottom surface 1180 of secondmold portion 1120 even after the fluid-filled chamber is fully molded.Although outsole 1060 is held in position during molding, demolding iscarried out with less force than demolding from a mold that exertsforces on such protuberances. Fluid pressure in fluid-filled chamber1065 may be adjusted after the sole structure is demolded. Fluidpressure in fluid-filled chamber 1065 may be adjusted after the solestructure is demolded.

Embodiments of the disclosure may be molded from any moldable sheetmaterial, such as thermoplastic polymer. Embodiments also may have anyfunction, and may have any shape that can be molded. Embodimentsaccommodate pressurization of the mold after the bottom layer of theobject is inserted into the mold so that the pressure will urge thelayer to contact the fixed object, the edges of the fixed object or ofthe mold, and urge the fixed object toward the mold.

In some embodiments, the shape of the co-molded article may produce acontainer. FIG. 12 and FIG. 13 depict a container having feet. Thecontainer may be first element 1260, which may be characterized as case1260. As depicted in FIG. 12, first element or case 1260 has been placedin second mold portion 1320. Case 1260 may have a foot or protuberance1235, with the foot having a bottom 1237. Second mold portion 1320 mayinclude bottom surface 1280. In some embodiments, bottom surface 1280may not contact each bottom 1237 of feet 1235. Case 1260 may have ashape that includes a slight arc. Thus, whether each bottom 1237 of feet1235 touches bottom surface 1280 depends upon the arrangement of feet1235 and whether case 1260 may have an arc when placed in second moldportion 1320. In such embodiments, an arc may be exhibited in objectedge 1262. As depicted in FIG. 12, object edge 1262 illustrates such anarc, as object edge 1262 is not in contact with mold edge 1362.

Placement of first and second polymer webs between first mold portion1310 and second mold portion 1320 in mold 1300 before closing the mold,as depicted in FIG. 13, is carried out in essentially the same manner asis the method described with regard to FIG. 7, FIG. 8, and FIG. 9.

In some embodiments, box top 1206, produced from a first polymer layer,may be adhered or otherwise affixed to a second polymer layer 1208 thatforms the remainder of the box at flange 1246. The top surface of boxtop 1206 is shaped by surface 1350 to form box surface 1212.

Fluid may be injected into the volume formed by second polymer layer1208 and box top 1206. The fluid may be a gas, a liquid, or a gel.Injection of fluid into box 1265 may urge second polymer layer 1208toward top surface 1246 of case 1260, edge 1262 of case 1260, and edge1362 of second mold portion 1320. As the pressure in box 1265 increases,pressure on first element bottom surface 1264 may urge bases 1237 onprotuberances 1235 toward surface 1280 of second mold portion 1320.Similarly, pressure in case 1260 may urge edge 1243 of second polymerlayer toward edge 1262 of case 1260, and may urge both toward edge 1362of second mold portion 1320. Edge 1243 also may be urged into contactwith edge 1362 of second mold portion 1320 where edge 1262 of case 1260does not preclude contact therewith.

As can be seen with particularity in FIG. 13, bottom surface 1294 ofcase 1260 typically may not contact bottom surface 1390 of second moldportion 1320 even after the case is fully molded. Although case 1260 isheld in position, demolding is carried out with less force thandemolding from a mold that exerts forces on such protuberances 1235.Fluid pressure in box 1265 may be adjusted after the co-molded articleis demolded.

Embodiments include articles made in accordance with the methoddisclosed herein. Embodiments of these articles may be a sole structurefor an article of footwear, as described herein. Such a sole structuremay be attached to an upper for an article of footwear to produce anarticle of footwear. The upper for an article of footwear may be anysuitable composition of material element. Such material elements mayinclude textiles, foams, leathers, and synthetic leathers, for example.More than one material may be present in an upper. The sole structuremay be affixed to the upper by adhesion, sewing, or stitching, or by anymethod known to the skilled practitioner.

FIG. 14 illustrates an article of footwear 3100 having a sole structure3130, which is secured to the outer periphery of an upper 3120, alsoshown in FIG. 15, or upper 120 of FIG. 1. The sole structure 3130 may besecured to a bottom surface of the upper 3120, or a strobel, lastingboard, or foam layer may be secured to the upper 3120 and the solestructure 3130 may secure to the bottom surface of the strobel, lastingboard, or foam layer. Sole structure 3130 is located under the foot andsupports the foot. The primary elements of sole structure 3130 are aforefoot sole structure 3131 and a heel sole structure 3132. The solestructure 3130 has a forefoot region 3134, a midfoot region 3133, and aheel region 3136 and extends from a medial side 3137 to a lateral side3138.

The forefoot sole structure 3131 includes a forefoot midsole, which, inthe embodiment shown, is a polymeric bladder element 3140, and is alsoreferred to as a forefoot component, forefoot bladder element, or afluid-filled chamber. The polymeric bladder element 3140 is best shownin FIG. 16. The polymeric bladder element 3150 is best shown in FIG. 20.The bladder element 3140 encloses a fluid-filled interior cavity 3142indicated in FIGS. 15 and 16. Similarly, the heel sole structure 3132includes a heel midsole, which, in the embodiment shown, is a polymericbladder element 3150, and is also referred to as a heel component, heelbladder element, or a fluid-filled chamber. The bladder element 3150encloses a fluid-filled interior cavity 3152 indicated in FIGS. 15 and20. The bladder elements 3140, 3150 are between the outsole componentsof the bottom view of FIG. 14 and the upper 3120, as best shown in FIG.15.

The bladder elements 3140 and 3150 are separate from one another and arenot in fluid communication with one another. The bladder element 3140has multiple tubular portions with arcuate shapes (e.g., generally Ushaped) so that the fluid-filled interior cavity 3142 has correspondingtubular portions 3142A, 3142B, 3142C, 3142D, and 3142E interconnectedand in fluid communication with one another by channels 3143 as bestshown in FIG. 16. The bladder element 3150 has multiple interconnectedportions arranged in a U-shape so that the fluid-filled interior cavity3152 has multiple portions 3152A, 3152B, 3152C, 3152D and 3152Einterconnected and in fluid communication with one another by channels3153, as best shown in FIG. 20. The polymeric bladder element 3140 isconfigured so that arcuate portions of the fluid-filled interior cavity3142 are at an outer periphery in the forefoot region 3134 of the solestructure 3131 as shown in FIG. 15. The bladder element 3140 has arcuatetubular portions 3149 in the forefoot region of the sole structure, asbest shown in FIG. 16. The arcuate tubular portions 3149 have innercurved walls 3151 with tighter curvature than the outer walls of thearcuate tubular portions 3149. Stated differently, the inner curvedwalls 3151 are at the inside of the U-shaped arcuate tubular portions3149. The side surface 3079 of the bladder element 3140 to which thefirst wall of the first outsole component is secured is at the innercurved wall 3151. The inner wall 3099 can thus support and reinforceboth the second wall 3087 and the inner curved wall 3151 of the bladderelement 3140 at the arcuate tubular portion during flexing of theforefoot region. This support and reinforcement should reduce stresseson the second wall 3087 to prevent cracking of the second wall 3087.

The bladder elements 3140, 3150 may each be thermoformed from upper andlower sheets 3144, 3146 as shown in FIGS. 24 and 27 and described herein(also referred to as first and second sheets, first and second layers,or upper and lower layers), or, in the alternative, may be blow-molded.The sheets may have alternating layers of TPU and a gas barriermaterial. In any embodiment, each bladder element 3140, 3150 isconfigured to retain fluid within the fluid-filled interior cavities3142, 3152. As used herein, a “fluid” includes a gas, including air, aninert gas such as nitrogen, or another gas. Accordingly, “fluid-filled”includes “gas-filled”. The various materials used for the bladderelements 3140, 3150 may be substantially transparent or may have atinted color. For example, the bladder elements 3140, 3150 can be formedfrom any of various polymeric materials that can retain a fluid at apredetermined pressure, including a fluid that is a gas, such as air,nitrogen, or another gas. For example, the bladder elements 3140, 3150can be a thermoplastic urethane (TPU) material, a urethane,polyurethane, polyester, polyester polyurethane, and/or polyetherpolyurethane.

Moreover, in one embodiment, the bladder elements 3140, 3150 can beformed of one or more sheets having layers of different materials. Thesheets may be laminate membranes formed from thin films having one ormore first layers that comprise thermoplastic polyurethane layers andthat alternate with one or more second layers, also referred to hereinas barrier layers, gas barrier polymers, or gas barrier layers. Thesecond layers may comprise a copolymer of ethylene and vinyl alcohol(EVOH) that is impermeable to the pressurized fluid contained therein asdisclosed in U.S. Pat. No. 6,082,025 to Bonk et al., which isincorporated by reference in its entirety. The first layer may bearranged to form an outer surface of the polymeric sheet. That is, theoutermost first layer may be the outer surface of the bladder element3140 or 3150. The bladder elements 3140, 3150 may also be formed from amaterial that includes alternating layers of thermoplastic polyurethaneand ethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos.5,713,141 and 5,952,065 to Mitchell et al. which are incorporated byreference in their entireties. Alternatively, the layers may includeethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and aregrind material of the ethylene-vinyl alcohol copolymer andthermoplastic polyurethane. Each sheet may also be a flexible microlayermembrane that includes alternating layers of a gas barrier polymermaterial such as second layers and an elastomeric material such as firstlayers, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonket al. which are incorporated by reference in their entireties.Additional suitable materials for the bladder elements 3140, 3150 aredisclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy which areincorporated by reference in their entireties. Further suitablematerials for the bladder elements 3140, 3150 include thermoplasticfilms containing a crystalline material, as disclosed in U.S. Pat. Nos.4,936,029 and 5,042,176 to Rudy, and polyurethane including a polyesterpolyol, as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868, and6,321,465 to Bonk et al. which are incorporated by reference in theirentireties. In selecting materials for the bladder elements 3140, 3150,engineering properties such as tensile strength, stretch properties,fatigue characteristics, dynamic modulus, and loss tangent can beconsidered. When the bladder element 3140 or 3150 is formed from sheets,the thicknesses of the sheets used to form the bladder element 3140 or3150 can be selected to provide these characteristics.

Forefoot bladder element 3140 and heel bladder element 3150 are formedfrom a polymer material that encloses a fluid, which may be a gas,liquid, or gel. During walking and running, for example, forefootbladder element 3140 and heel bladder element 3150 may compress betweenthe foot and the ground, thereby attenuating ground reaction forces.That is, after thermoforming, forefoot bladder element 3140 and heelbladder element 3150 are inflated and generally pressurized with thefluid to cushion the foot. FIG. 14 shows sealed inflation ports 3155through which fluid is introduced into the interior cavities 3142, 3152prior to sealing.

In some configurations, sole structure 3130 may include a foam layer,for example, that extends between upper 3120 and one or both of forefootbladder element 3140 and heel bladder element 3150, or a foam elementmay be located within indentations in the lower areas of forefootbladder element 3140 and heel bladder element 3150. In otherconfigurations, forefoot sole structure 3131 may incorporate plates,moderators, lasting elements, or motion control members that furtherattenuate forces, enhance stability, or influence the motions of thefoot. Heel sole structure 3132 also may include such members to furtherattenuate forces, enhance stability, or influence the motions of thefoot.

The forefoot sole structure 3131 also includes a first outsole component3060 secured to the bladder element 3140, and multiple second outsolecomponents 3062 secured to the first outsole component 3060 as describedherein. The first outsole component 3060 is shown in isolation in FIGS.17 and 18. The second outsole component 3062 is secured to the firstoutsole component in FIG. 14. The heel sole structure 3132 includes afirst outsole component 3070, and a second outsole component 3072secured to the first outsole component 3070 as described herein. Thefirst outsole component 3070 is shown in FIGS. 21 and 22. The secondoutsole component 3072 is secured to the first outsole component 3070 asshown in FIG. 14. FIG. 15 shows the first outsole components 3060, 3070secured to the bladder elements 3140 and 3150, with the second outsolecomponents 3062, 3072 removed.

In addition to providing a wear surface (i.e., a ground-engagingsurface) of an article of footwear, forefoot outsole component 3060 andheel outsole component 3070 may enhance various properties andcharacteristics of sole structure 3130. Properties and characteristicsof the outsoles, such as the thickness, flexibility, the properties andcharacteristics of the material used to make the outsole, and stretch,may be varied or selected to modify or otherwise tune the cushioningresponse, compressibility, flexibility, and other properties andcharacteristics of sole structure 3130. In the embodiment shown, thefirst outsole components are a first material and the second outsolecomponents are a second material different than the first material. Thefirst outsole components 3060 and 3070 are injection moldedthermoplastic polyurethane (TPU) components that are preformed withtheir desired shape and configuration by the injection molding processprior to being thermally bonded to the respective bladder element 3140,3150 by the method described herein. The second outsole components 3062,3072 are rubber and are preformed in their desired shape and thensecured to the first outsole component 3060 or 3070 as described herein.First outsole component 3060 is a single, unitary, one-piece component,and first outsole component 3070 is a single, unitary, one-piececomponent. Each of the second outsole components 3062 and 3072 are alsosingle, unitary, one-piece components.

Forefoot outsole component 3060 is secured to a lower surface offorefoot bladder element 3140. In some embodiments, forefoot solestructure 3131 may extend into a midfoot region. The forefoot outsolecomponent 3060 also may be secured to lower areas of forefoot bladderelement 3140 in a midfoot region. Heel outsole component 3070 is securedto lower areas of heel bladder element 3150. Both heel bladder elements3150 and heel outsole component 3070 may extend into a midfoot region.Forefoot outsole component 3060 and heel outsole component 3070 may beformed from a wear-resistant material. The wear-resistant material maybe transparent or translucent to provide a visually appealing effect.The wear-resistant material may be textured on the ground-engagingsurface to impart traction, such as by including integral tread elements3135, 3091 as described herein. Any or all of the components of forefootsole structure 3131 and heel sole structure 3132 may be translucent ortransparent, and may be colored or patterned for aesthetic appeal.

FIGS. 14, 17 and 18 also illustrate gas escape openings 2069 in thefirst outsole component 3060 of the forefoot sole structure 3131, andFIGS. 14, 21, and 22 illustrate gas escape openings 2079 in the firstoutsole component 3070 of the heel sole structure 3132 only some ofwhich are indicated with reference numbers. These gas escape openingsallow air or other gases trapped between a bladder element and thecorresponding outsole component during manufacturing to escape. Theinside surface of an outsole component may be shaped in a manner thatmay accumulate trapped gas and direct the entrapped gas to a gas escapeopening. For example, small interconnected grooves 2071 may be formed onthe inside surface of the outsole component 3060 during injectionmolding, or may be provided in the surface by removal of material aftermolding. The gas escape openings 2069 are in the bottom of the grooves2071, as shown in FIG. 19. The second outsole component 3070 also hasgrooves 2071 on the inner surface, as shown in FIG. 22, that directentrapped gas to the gas escape openings 2079. The gas escape openings2079 are in fluid communication with the grooves 3071.

Reinforcement of the outsole (for example, inclusion of structuralelements, such as ribs), apertures, the height of the walls of theoutsole, the number and location of the walls of outsole and walls ofthe bladder elements (also referred to as edges of the bladder elements)that overlap, or other features of an outsole all may be used to tunethe responses of the sole structure. In particular, overlap of a wall ofan outsole component with the side walls of a forefoot bladder elementor a heel bladder element, or with the sidewalls of an underlyingoutsole component, such as described and illustrated at least in FIGS.14-28, may be used to tune the elastic response and cushioning responseof the resultant sole structure. With the guidance provided herein,these and other properties and characteristics of the outsole incombination with the properties and characteristics of the fluid-filledbladder elements can be selected and configured to provide a desiredcushioning response.

In the embodiment shown in FIGS. 14-28 and manufactured as describedwith respect to FIGS. 25-28, the configuration of the first outsolecomponents 3060 and 3070 supports the respective bladder elements 3140and 3150 and allows a second outsole component 3062 or 3072 to bereceived and nested partially within a recess 4050 in the first outsolecomponent 3060, or within a recess 4150 in the first outsole component3070. The recesses 4050 and 4150 provide positioning guidance duringassembly and, as discussed herein, protect the second outsole components3062 and 3072 from delamination during wear. Moreover, both the firstoutsole components 3060, 3070 and the second outsole components 3062,3072 have tread elements 3135, 3091, respectively, that establish aground-engaging surface of the sole structure (contacting the ground Gin FIG. 24), enabling different tractive properties to be provided atthe locations of the tread elements 3135, 3091, by using differentshapes, sizes of the tread elements 3135, 3091, and/or by usingdifferent materials for the first and second outsole components 3060 and3062. The tread elements 3135, 3091 may be protrusions, ridges, orground-engaging lugs or sections that impart traction. As shown in FIG.14, the tread elements 3135 have different sizes and shapes includingrectangular and trapezoidal. The tread elements 3091 are generallylarger than the tread elements 3135. Depending on the materials used forthe outsole components 3060, 3062, 3070, 3072, the second outsolecomponents 3062, 3072 may provide increased traction relative to thefirst outsole components 3060, 3070, or decreased traction.

The tread elements 3135 of the first outsole component 3060, 3070 are anintegral portion of the first outsole component (i.e., formed togetherwith the base and walls by injection molding of the first outsolecomponent) as best shown in FIGS. 17 and 20, and the tread elements 3091of the second outsole component 3062 or 3072 are likewise an integralportion of the one-piece, unitary second outsole component 3062 or 3072.Configuration of the outsole components in this manner simplifiesmanufacturing and lessens the possibility of separation of the treadelements from the base of the outsole component during wear.

FIGS. 17 and 18 show the first outsole component 3060 prior toattachment of the second outsole component 3062. FIGS. 21 and 22 showthe first outsole component 3070 prior to attachment of the secondoutsole component 3072. FIGS. 23 and 24 show the first outsole component3060 attached to a bottom surface 3080 of the bladder element 3140 andto side surfaces 3078, 3079 of the bladder element 3140. Morespecifically, the first outsole component 3060 has a first base 3083attached to the bottom surface 3080 of the bladder element 3140, a firstwall 3085 integral with the first base 3083 secured to a side surface3078 of the bladder element 3140, and a second wall 3087 integral withthe first base 3083 and secured to a side surface 3079 of the bladderelement 3140. As indicated by the location of the cross-sections ofFIGS. 23 and 24 in FIG. 14, and as shown in FIG. 18, the first wall 3085and the second wall 3087 are at the arcuate portion of the fluid-filledinterior cavity 3142. The second wall 3092 of the second outsolecomponent 3062 is at the arcuate portion.

The first outsole component 3060 has integral tread elements 3135 atpredetermined portions of the bottom surface 3081 of the first outsolecomponent, while other portions are free from tread elements. FIG. 24shows a base 3083 of the first outsole component 3060 attached to thefirst bladder element 3140 and having integral tread elements 3135 atfirst portion 3082 of a bottom surface 3081 of base 3083. Second portion3084 of the bottom surface 3081 of base 3083 is free from any treadelements 3135. The other portion of the first outsole component 3060shown attached to the bladder element 3140 also has a base 3083 andwalls 3085, 3087 integral with the base 3083, with a first portion 3082of the base 3083 with integral tread elements 3135 and a second portion3084 free from any tread elements. At least some of the tread-freeportions are free from tread elements 3135 specifically because a secondoutsole component 3062 with its own integral tread element(s) is to beattached at the second portion 3084, as shown in FIG. 14. As such, notread elements of the first outsole component 3060 will interfere withattachment of the second outsole component 3062.

The second outsole component 3062 has a second base 3090 and optionallyincludes one or more integral tread elements 3091. The second base 3090is secured to the second portion 3084 of the bottom surface 3081 of thefirst base 3083. The second outsole component 3062 has a second wall3092 integral with the second base 3090. The second wall 3092 is securedto the outer surface 3094 of the first wall 3085 of the first outsolecomponent 3060. The outer surface 3094 is adjacent the second portion3084 of the bottom surface 3081. With this configuration, aground-engaging surface 3098 of the sole structure 3131 includesintegral tread elements 3135 of the first outsole component 3060, andintegral tread elements 3091 of the second outsole component 3062.

Similarly, as best shown in FIGS. 21 and 22, the first outsole component3070 of the heel sole structure 3132 has integral tread elements 3135 atpredetermined portions of the bottom surface 4002 of the first outsolecomponent 3070, such as at first area 4004, and has a second area 4006free from any tread elements. The first outsole component 3070 has afirst base 4008 and an integral first wall 4010 extending from the firstbase adjacent the second area 4006. The first wall 4010 is an outerwall. The first outsole component 3070 also has a second wall, referredto as an inner wall 4011, which is integral with the first base 4008.

The second outsole component 3072 has a second base 4012 secured to thefirst base 4008. The second outsole component 3072 has a second wall4014 (i.e., outer wall) integral with the second base 4012 and securedto the outer surface 4016 of the first wall 4010. The second outsolecomponent 3072 has an inner wall 4015 integral with the second base 4012and secured to the outer surface 4017 of the second wall 4011 as isevident in FIGS. 14, 15, and 21.

As best shown in FIG. 23, the first outsole component 3060 has anarcuate shape corresponding to the arcuate shape of the fluid-filledinterior cavity 3142 with the first wall 3085 at the outer periphery ofthe arcuate portion of the fluid-filled interior cavity 3142. The secondwall 3092 of the second outsole component 3062 is also at the arcuateportion. The first wall 3085 and second wall 3092 are thus outer walls.The second wall 3087 of the first outsole component 3060 is an innerwall located at the inner curve of the arcuate portion. The inner wall3099 of the second outsole component 3062 is also at the inner curve ofthe arcuate portion. Supporting the tubular arcuate portions of thebladder elements with the outer and inner walls of the outsolecomponents 3060, 3070 provides support, acting as a geometric constrainton the bladder element 3140, and provides stiffness, tuning thecushioning response of the bladder element 3140.

Reinforcement of the outsole components 3060, 3062, 3070, 3072 (forexample, inclusion of structural elements, such as ribs), apertures, theheight of the walls 3085, 3087, 3092, 3099 of the outsole components3060, 3062, 3070, 3072, the number and location of overlapping walls ofoutsole components 3060, 3062, 3070, 3072 and of the bladder elements3140, 3150 (also referred to as edges of the bladder elements), or otherfeatures of outsole components 3060, 3062, 3070, 3072 all may be used totune the responses of the sole structures 3131 and 3132. In particular,overlap of a wall 3085, 3087, 4010, 4011 of a first outsole component3060, 3070 away from the respective base portion 4008 and up the sidesurface 3078, 3079 of a forefoot bladder element 3140, or the sidesurface of a heel bladder element 3150, and overlap of a wall 3092,3099, 4014 of a second outsole component 3062, 3072 away from therespective base portion and up the wall 3085, 3087, 4010, 4011 of therespective first outsole component 3060, 3070 such as described andillustrated at least in FIGS. 15-24, may be used to tune the elasticresponse and cushioning response of the resultant sole structure 3131,3132. With the guidance provided herein, these and other properties andcharacteristics of the outsole components 3060, 3062, 3070, 3072 incombination with the properties and characteristics of the fluid-filledbladder elements 3140, 3150 can be selected and configured to provide adesired cushioning response.

The first outsole component 3060 and the second outsole component 3062are cooperatively configured to fit together to assist with locating thesecond outsole component 3062 on the first outsole component 3060 and toreduce the possibility of the second outsole component 3062 separatingfrom the first outsole component 3060 during wear. More specifically,and as best shown in FIG. 24, the outer surface of 3094 the first wall3085 of the first outsole component 3060 has a recess 4050. When theforefoot sole structure 3131 is thermoformed, the recess 4050 isadjacent the second portion 3084 of the bottom surface 3081 of the firstoutsole component 3060 as shown in FIG. 24. With reference to FIGS. 25and 26, the recess 4050 is provided due to the shape of the injectionmold 5010 in which the first outsole component 3060 is injection molded.In an embodiment, the injection mold 5010 may have upper and lower molds5012, 5014 with mold surfaces 5016, 5018, respectively. TPU material isinjected through ports 5020 in molding the first outsole component 3060to the contours of the mold surfaces 5016, 5018. A protrusion 5022 inthe lower mold 5014 causes the recess 4050 in the first wall 3085 of themedial side of the first outsole component 3060. A similar protrusion5022 causes the recess 4050 in the first wall 3085 of the lateral sideof the first outsole component 3060. The mold surface 5018 also hasrecesses 5026 that create the tread elements 3135. Additionally, themold surfaces 5016, 5018 are shaped so that the second walls 3087 (i.e.,the inner walls) of the first outsole component 3060 have a greaterheight than the first walls 3085 (i.e., the outer walls) of the firstoutsole component 3060 and so that an upper end 4070, 4072 of the walls3085, 3087 are tapered.

The second wall 3092 of the second outsole component 3062 is configuredso that it can fit in and be secured to the outer surface of the firstwall 3085 of the first outsole component 3060 in the recess 4050. Thefirst outsole component 3070 and the second outsole component 3072 ofthe heel sole structure 3132 are cooperatively configured in the samemanner.

Moreover, as shown in FIG. 24, the second wall 3092 has a firstthickness T1 and the recess 4050 has a first depth D1. The firstthickness T1 is greater than the first depth D1 so that second outsolecomponent 3062 protrudes outward of the first outsole component 3060 atthe first wall 3085. The upper edge 4060 of the second outsole component3062 is abutted against or just below a lip 4062 of the first outsolecomponent 3060 in the recess 4050. The lip 4062 protects the upper edge4060 from direct applied forces during use, reducing the possibility ofdelamination or other dislocation of the second outsole component 3062.

As best shown in FIG. 23, the inner wall 3099 of the second outsolecomponent 3062 extends upward from the second base 3090 of the secondoutsole component further than the second wall 3092 (i.e. the outerwall) of the second outsole component. Support for the bladder element3040 at the inner wall 3099 is desirable to limit inward movement of thebladder element 3040 during compression and deformation. The secondoutsole component 3072 of the bladder element 3050 may be similarlyconfigured, with inner walls that extend upward along inner walls of thefirst outsole component 3070 further than outer walls.

In the embodiment shown, the recess 4050 extends across the bottomsurface and up the outer surface of the inner wall 3087 of the firstoutsole component 3060. Accordingly, only a portion of the thickness T2of the inner wall 3099 of the second outsole component 3062 protrudesfrom the outer surface of the inner wall 3087 of the first outsolecomponent 3060 as shown in FIG. 23. Alternatively, the recess 4050 mayend at the bottom surface so that the inner wall 3087 may be configuredwithout a recess. Both the outer wall 3085 and the inner wall 3087 ofthe first outsole component 3060 have a tapered upper end 4070, 4072,shown in FIG. 18, helping to prevent delamination of the first outsolecomponent 3060 from the bladder element 3140. The first outsolecomponent 3070 is similarly configured with a tapered upper end 4073 atthe first wall 4010. The upper end 4074 of the first outsole component3070 continues up the inner wall of the tubular portion of the lowerpolymer sheet 3146 of the bladder element 3050 to the lower surface ofthe lower polymer sheet 3146 adjacent the tubular portion as indicatedin FIGS. 14 and 22, providing maximum support against the inner wall ofthe bladder element 3150.

A method of manufacturing an article of footwear that includes the solestructure 3131 and/or the sole structure 3132 as described aboveincludes placing a preformed first outsole component 3160 into athermoforming mold 6012, 6014. In FIG. 27, the thermoforming mold isschematically depicted as including an upper mold 6012 and a lower mold6014. As described with respect to FIGS. 25 and 26 and shown in FIGS. 17and 18, the first outsole component 3060 is preformed with a base 3083having integral tread elements 3135 protruding from a first portion 3082of a bottom surface 3081 of the base, with a second portion 3084 of thebottom surface 3081 free of any tread elements, and with a wall 3085integral with the base 3083 and adjacent the second portion 3084 of thebottom surface. As used herein, “preformed” means that the first outsolecomponent 3060 has the features prior to the thermoforming process(i.e., prior to placement in the thermoforming mold 6012, 6014).

In an embodiment, the lower mold 6014 may have one or more positioningmarkers to orient the first outsole component 3060. As shown in FIG. 27,the second mold surface 6018 has a positioning marker 6024, and placingthe first outsole component 3060 into the lower mold 6014 includesplacing a predetermined portion of the first outsole component 3060 atthe positioning marker 6024, thereby orienting the first outsolecomponent 3060 in a predetermined position in the thermoforming mold6014. The positioning marker 6024 is a cavity in the second mold surface6018, and the predetermined portion of the first outsole component 3060is one of the tread elements 3135. Other alternative positioning markersmay be used instead of or in addition to positioning marker 6024.

The method further includes placing polymeric material in thethermoforming mold 6012, 6014 with the first outsole component 3060. Thepolymeric material may be a first polymeric sheet 3144 and a secondpolymeric sheet 3146 also referred to as an upper polymeric sheet and alower polymeric sheet due to their relative positions in the completedarticle of footwear. Alternatively, the polymeric material may be apreform (e.g., polymeric material not in sheet form).

The thermoforming mold 6012, 6014 is then closed by placing the upperand lower molds 6012, 6014 together as shown in FIG. 28 to enclose thepolymeric material (i.e., an enclosed portion of the sheets 3144, 3146and the first outsole component 3060 in a mold cavity 6028 definedbetween the mold surface 6026 of the upper mold 6012 and the moldsurface 6018 of the lower mold 6014. The method then includes formingthe sheets 3144, 3146 by a combined thermoforming and vacuuformingprocess, which includes applying a vacuum to conform a first portion ofthe polymeric material (i.e., the enclosed portion of the first sheet3144) to the first mold surface (i.e., the surface 6026) of thethermoforming mold and conform a second portion of the polymericmaterial (i.e., the bottom surface 3080 of the enclosed portion of thesecond sheet 3146) to an upper surface 3088 of the first outsolecomponent 3060 and to the second mold surface 6018 with the interiorcavity 3142 between the first sheet 3144 and the second sheet 3146. InFIG. 28, the lip 4062 of the first outsole component 3060 is notapparent as it is compressed against the mold surface 6018. The interiorcavity 3142 may be inflated after the thermoforming process is complete(i.e., after removal of the bladder element 3140 and first outsolecomponent 3060 from the thermoforming mold 6012, 6014). Gaps may existbetween the bottom surface of the first outsole component 3060 and themold surface 6018 to ease removal of the sole surface afterthermoforming.

In an embodiment in which the polymeric material is the first and secondpolymer sheets 3144, 3146, the method then includes thermally bondingthe first polymeric sheet 3144 to the second polymeric sheet 3146 toenclose the interior cavity 3142, and thermally bonding the lowersurface 3080 of the second polymer sheet 3146 to the upper surface 3088of the first outsole component.

The first and second polymer sheets 3144, 3146 are thermally bonded toone another around the peripheral flange 3148 formed between the pinchsurface 6030 and the seam-forming surface 6070 and at web areas 3147between the portions of the fluid-filled interior cavity 3142. As themold 6012, 6014 closes, pinch surface 6030 contacts and slides against aportion of second seam-forming surface 6070. The contact between pinchsurface 6030 and second seam-forming surface 6070 effectively seversexcess portions 6810, 6820 of first and second polymer sheets 3144, 3146from portions that form bladder element 3140. The material forming firstpolymer sheet 3144 and second polymer sheet 3146 compacts or otherwisecollects to form flange 3148. In addition to forming flange 3148, firstpolymer sheet 3144 and second polymer sheet 3146 are (a) shaped toproduce bladder element 3140 and (b) compressed and joined to produceweb area 3147.

The thermoformed sheets 3144, 3146 are allowed to cool, and then themold 6012, 6014 is opened by separating the upper and lower molds 6012,6014, and the thermally bonded upper and lower polymer sheets 3144, 3146and first outsole component 3060 are removed from the mold 6012, 6014 asa unit after a predetermined cooling period. If the mold 6012, 6014 isconfigured to mold multiple sole structures 3131, 3132 simultaneously,additional trimming may be necessary around the flange 3148 or betweenthe adjacent sole structures. The bladder element 3140 with the attachedfirst outsole component 3060 may be inflated after thermoforming andprior to attachment of the second outsole component 3062, or may beinflated after attachment of the second outsole component 3062.

After the first outsole component 3060 is attached to the bladderelement 3140, the second outsole component 3062 is positioned on thesecond portion 3084 of the bottom surface 3080 of the first outsolecomponent 3060. Positioning the second outsole component 3062 is bynesting the second outsole component 3062 in the recess 4050. Nestingincludes abutting the upper edge 4060 of the second outsole component3062 against the lip 4062 of the first outsole component 3060 at anupper extent of the recess 4050, as indicated with respect to one of theoutsole components 3062 in FIG. 15. The upper edge 4060 of the secondoutsole component 3062 is abutted against a lip 4062 of the firstoutsole component 3060 in the recess 4050, as shown in FIGS. 15, 23, and24. The second outsole component 3062 is adhered to the first outsolecomponent 3060. As shown in FIG. 15, the footwear upper 3120 is thensecured to the upper surface 4041 of the first polymer sheet 3144. InFIG. 15, the flange 3148 is shown at the lateral side of the solestructure 3130 and is adhered to the lower lateral side of the upper3120.

The method has been described with respect to the forefoot solestructure 3131. The method may also include injection molding the firstoutsole component 3070, vacuum/thermoforming the bladder element 3150and thermally bonding the first outsole component 3070 to the bladderelement 3150 in a thermoforming mold, attaching the second outsolecomponent 3072 to the first outsole component 3070 as described, andthen securing the heel sole structure 3132 to the heel region of theupper 3120 with a forward edge 3110 of the heel sole structure adjacenta rearward edge 3112 of the forefoot sole structure as shown in FIGS. 14and 15.

While several modes for carrying out the many aspects of the presentteachings have been described in detail, those familiar with the art towhich these teachings relate will recognize various alternative aspectsfor practicing the present teachings that are within the scope of theappended claims. It is intended that all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative only and not as limiting.

The invention claimed is:
 1. A method of manufacturing an article offootwear comprising: placing a preformed first outsole component in athermoforming mold; wherein the preformed first outsole component has: abase with integral tread elements protruding from a first portion of abottom surface of the base, and with a second portion of the bottomsurface free of any tread elements; and an outer wall integral with thebase and adjacent the second portion of the bottom surface and an innerwall integral with the base; placing a first polymeric sheet and asecond polymeric sheet in the thermoforming mold with the first outsolecomponent; closing the thermoforming mold to enclose the first polymericsheet, the second polymeric sheet, and the first outsole component in amold cavity; applying a vacuum to conform the first polymeric sheet to afirst mold surface of the thermoforming mold and to conform the secondpolymeric sheet to an upper surface of the first outsole component andto a second mold surface of the thermoforming mold, thereby defining aninterior cavity between the first polymeric sheet and the secondpolymeric sheet; thermally bonding the first polymeric sheet to thesecond polymeric sheet to enclose the interior cavity; thermally bondinga lower surface of the second polymer sheet to the upper surface of thefirst outsole component; removing the first polymer sheet, the secondpolymer sheet, and the first outsole component from the thermoformingmold as a unit; positioning a second outsole component on the secondportion of the bottom surface of the base; and adhering the secondoutsole component to the first outsole component so that the secondoutsole component extends along the bottom surface of the base, partwayup the outer wall, and partway up the inner wall.
 2. The method of claim1, wherein removing the first polymeric sheet, the second polymericsheet, and the first outsole component from the thermoforming mold as aunit is performed after a predetermined cooling period.
 3. The method ofclaim 1, wherein: the first outsole component has a recess; and saidpositioning the second outsole component is performed by nesting thesecond outsole component in the recess.
 4. The method of claim 3,wherein said nesting includes placing an upper edge of the secondoutsole component along a lip of the first outsole component at an upperextent of the recess.
 5. The method of claim 4, wherein: the recessextends along the bottom surface of the base, partway up the outer wall,and further up the inner wall than the outer wall.
 6. The method ofclaim 1, wherein, after adhering the second outsole component to thefirst outsole component, the first polymeric sheet, the second polymericsheet, the first outsole component, and the second outsole component areconfigured as a forefoot sole structure, the method further comprising:securing the forefoot sole structure to a forefoot region of a footwearupper; and securing a heel sole structure to a heel region of thefootwear upper with a forward edge of the heel sole structure adjacent arearward edge of the forefoot sole structure.
 7. The method of claim 1,further comprising: securing a footwear upper to an upper surface of thefirst polymeric sheet.
 8. The method of claim 1, wherein: the secondmold surface has a positioning marker; and placing the first outsolecomponent in the thermoforming mold includes placing a predeterminedportion of the first outsole component at the positioning marker,thereby orienting the first outsole component in a predeterminedposition in the thermoforming mold.
 9. The method of claim 1, whereinthe second outsole component and the integral tread elements of thefirst outsole component together establish a ground-engaging surface ofthe article of footwear.
 10. A method of manufacturing an article offootwear comprising: placing a preformed first outsole component in athermoforming mold; wherein the preformed first outsole component has: abase with integral tread elements protruding from a first portion of abottom surface of the base, and with a second portion of the bottomsurface free of any tread elements; and a wall integral with the baseand adjacent the second portion of the bottom surface; wherein the firstoutsole component has a recess in an outer surface of the wall; placinga first polymeric sheet and a second polymeric sheet in thethermoforming mold with the first outsole component; closing thethermoforming mold to enclose the first polymeric sheet, the secondpolymeric sheet, and the first outsole component in a mold cavity;applying a vacuum to conform the first polymeric sheet to a first moldsurface of the thermoforming mold and to conform the second polymericsheet to an upper surface of the first outsole component and to a secondmold surface of the thermoforming mold, with an interior cavity betweenthe first polymeric sheet and the second polymeric sheet; thermallybonding the first polymeric sheet to the second polymeric sheet toenclose the interior cavity; thermally bonding a lower surface of thesecond polymer sheet to the upper surface of the first outsolecomponent; removing the first polymeric sheet, the second polymericsheet, and first outsole component from the thermoforming mold as a unitafter a predetermined cooling period; positioning a second outsolecomponent on the second portion of the bottom surface of the base bynesting the second outsole component in the recess; wherein said nestingincludes placing an upper edge of the second outsole component along alip of the first outsole component at an upper extent of the recess; andadhering the second outsole component to the first outsole component;wherein the wall is an outer wall, the first outsole component includesan inner wall integral with the base, and the recess extends along thebottom surface of the base, partway up the outer wall, and further upthe inner wall than the outer wall.
 11. The method of claim 10, wherein,after adhering the second outsole component to the first outsolecomponent, the first polymeric sheet, the second polymeric sheet, thefirst outsole component, and the second outsole component are configuredas a forefoot sole structure, the method further comprising: securingthe forefoot sole structure to a forefoot region of a footwear upper;and securing a heel sole structure to a heel region of the footwearupper with a forward edge of the heel sole structure adjacent a rearwardedge of the forefoot sole structure.
 12. The method of claim 10, furthercomprising: securing a footwear upper to an upper surface of the firstpolymeric sheet.
 13. The method of claim 10, wherein the second moldsurface has a positioning marker; and placing the first outsolecomponent in the thermoforming mold includes placing a predeterminedportion of the first outsole component at the positioning marker,thereby orienting the first outsole component in a predeterminedposition in the thermoforming mold.